U.S. patent number 5,591,236 [Application Number 08/544,373] was granted by the patent office on 1997-01-07 for polyacrylate emulsified water/solvent fabric cleaning compositions and methods of using same.
This patent grant is currently assigned to The Procter & Gamble Company. Invention is credited to Timothy C. Roetker.
United States Patent |
5,591,236 |
Roetker |
January 7, 1997 |
**Please see images for:
( Certificate of Correction ) ** |
Polyacrylate emulsified water/solvent fabric cleaning compositions
and methods of using same
Abstract
Aqueous cleaning compositions containing solvents such as butoxy
propoxy propanol (BPP) are emulsified using low levels of
polyacrylate emulsifiers. Thus, an emulsion comprising BPP, a
polyacrylate, optional surfactants, optional 1,2-octanediol and
water is applied to fabrics in a home dry cleaning operation.
Inventors: |
Roetker; Timothy C. (Fairfield,
OH) |
Assignee: |
The Procter & Gamble
Company (Cincinnati, OH)
|
Family
ID: |
27022227 |
Appl.
No.: |
08/544,373 |
Filed: |
October 17, 1995 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
413560 |
Mar 30, 1995 |
|
|
|
|
Current U.S.
Class: |
8/137; 510/281;
510/284; 510/295; 510/341; 510/342; 510/350; 510/351; 510/356;
510/357; 510/361; 510/426; 510/427; 510/433; 510/476; 510/505;
510/506; 8/142 |
Current CPC
Class: |
C11D
3/3765 (20130101); C11D 3/43 (20130101); C11D
7/5022 (20130101); C11D 17/047 (20130101); D06L
1/04 (20130101) |
Current International
Class: |
C11D
3/37 (20060101); C11D 3/43 (20060101); C11D
7/50 (20060101); D06L 1/00 (20060101); D06L
1/04 (20060101); C11D 17/04 (20060101); D06L
001/04 (); C11D 003/37 (); C11D 003/43 (); C11D
007/50 () |
Field of
Search: |
;252/174.24,DIG.2,DIG.19,170,171,547,551,173,DIG.14 ;8/137,142
;510/281,282,283,284,295,341,342,350,351,356,357,361,426,427,433,434,476,505,506 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
1005204 |
|
Feb 1977 |
|
CA |
|
1295912 |
|
Feb 1992 |
|
CA |
|
0208989 |
|
Jan 1987 |
|
EP |
|
0213500 |
|
Mar 1987 |
|
EP |
|
0216355 |
|
Apr 1987 |
|
EP |
|
0232530 |
|
Aug 1987 |
|
EP |
|
0261718 |
|
Mar 1988 |
|
EP |
|
261874 |
|
Mar 1988 |
|
EP |
|
286167 |
|
Oct 1988 |
|
EP |
|
0329209 |
|
Aug 1989 |
|
EP |
|
0334463 |
|
Sep 1989 |
|
EP |
|
0347110 |
|
Dec 1989 |
|
EP |
|
0402981 |
|
Dec 1990 |
|
EP |
|
0429172A1 |
|
May 1991 |
|
EP |
|
0491531 |
|
Jun 1992 |
|
EP |
|
503219 |
|
Sep 1992 |
|
EP |
|
0513948 |
|
Nov 1992 |
|
EP |
|
0527625 |
|
Feb 1993 |
|
EP |
|
595383 |
|
May 1994 |
|
EP |
|
0630965 |
|
Dec 1994 |
|
EP |
|
2021561 |
|
Nov 1970 |
|
DE |
|
2460239 |
|
Jul 1975 |
|
DE |
|
3904610 |
|
Aug 1990 |
|
DE |
|
4007362 |
|
Sep 1991 |
|
DE |
|
4129986 |
|
Nov 1993 |
|
DE |
|
53/058095 |
|
May 1978 |
|
JP |
|
61/014298 |
|
Jan 1986 |
|
JP |
|
61/085498 |
|
May 1986 |
|
JP |
|
62/252499 |
|
Nov 1987 |
|
JP |
|
63/051500 |
|
Mar 1988 |
|
JP |
|
02/206695 |
|
Aug 1990 |
|
JP |
|
05/171566 |
|
Jul 1993 |
|
JP |
|
06/049498 |
|
Feb 1994 |
|
JP |
|
06/049497 |
|
Feb 1994 |
|
JP |
|
06/146041 |
|
May 1994 |
|
JP |
|
1397475 |
|
Jun 1975 |
|
GB |
|
1598911 |
|
Sep 1981 |
|
GB |
|
WO91/09104 |
|
Jun 1991 |
|
WO |
|
WO91/11505 |
|
Aug 1991 |
|
WO |
|
WO91/13145 |
|
Sep 1991 |
|
WO |
|
WO92/19713 |
|
Nov 1992 |
|
WO |
|
WO93/04151 |
|
Mar 1993 |
|
WO |
|
WO93/06204 |
|
Apr 1993 |
|
WO |
|
WO93/25654 |
|
Dec 1993 |
|
WO |
|
WO94/05766 |
|
Mar 1994 |
|
WO |
|
WO94/09108 |
|
Apr 1994 |
|
WO |
|
96/04358A1 |
|
Feb 1996 |
|
WO |
|
Other References
US. Application No. 08/545,441 Inventor Davis Filing Date Oct. 17,
1995. .
U.S. Application No. 08/544,228 Inventor Siklosi Filing Date Oct
17, 1995. .
U.S. Application No. 08/544,234 Inventors Siklosi & Yeazell
Filing Date Oct. 17, 1995. .
U.S. Application No. 08/544,235 Inventor Roetker Filing Date Oct.
17, 1995. .
U.S. Application No. 08/544,354 Inventors Young, Bavely, Filing
Date Oct. 17, 1995. .
U.S. Application No. 08/544,229 Inventors Trinh & Siklosi
Filing Date Oct. 17, 1995. .
U.S. Application No. 08/545,442 Inventors Roetker & Masters
Filind Date Oct. 17, 1995. .
U.S. Application No. 08/543,970 Inventors Siklosi & DesMarais
Filind Date Oct. 17, 1995. .
U.S. Application No. 08/544,239 Inventor Hortel Filing Date Oct.
17, 1995. .
Hunt, D. G. and N. H. Morris, "PnB and DPnB Glycol Ethers", HAPPI,
Apr. 1989, pp. 78-82. .
Trautwein, K., J. Nassal, Ch. Kopp & L. Karle, "The
Disinfectant Action of Glycols on Tuberculosis Organisms and Their
Practical Application", Monatsh. Tierheilk, vol. 7, Suppl. (1955)
pp. 171-187. (Abstract only). .
Iig, H., & H. Fischer, "Synthesis and Application of
Propoxylized Alcohols", Text.-Prax., vol. 25, No. 8, (1970), pp.
484-487 (Abstract only). .
Komarova, L. F., U. N. Garber & L. G. Chub, "Physical
Properties of Monoethers of Mono-and Diglycols", Zh. Obshch. Khim.,
vol. 40, No. 11 (1970), p. 2534, Russian (Abstract only). .
Sokolowski, A. & J. Chlebicki, "The Effect of Polyoxypropylene
Chain Length in Nonionic Surfactants on Their Adsorption at the
Aqueous Solution-Air Interface", Tenside Deterg., vol. 19, No. 5
(1982), pp. 282-286 (Abstract only). .
Hamlin, J. E., "Propylene Glycol Ethers and Esters in Solvent-Based
Paint Systems", Congr. FATIPEC, 17th (4), (1984), pp. 107-122
(Abstract only). .
DeFusco, A. J., "Coalescing Solvents for Architectural and
Industrial Waterborne Coatings", Proc. Water-Borne Higher-Solids
Coat. Symp., 15th, (1988), pp. 297-330 (Abstract only). .
Vance, R. G., N. H. Morris & C. M. Olson, "Coupling Solvent
Effects on Water -Reducible Alkyd Resins", Proc. Water-Born
Higher-Solids Coat. Symp., 16th (1989), pp. 269-282 (Abstract
only). .
Szymanowski, J., "The Estimation of Some Properties of Surface
Active Agents", Tenside, Surfactants, Deterg., vol. 27, No. 6
(1990), pp. 386-392 (Abstract only). .
Spauwen, J., R. Ziegler & J. Zwinselman, "New Polypropylene
Glycol-based Solvents for Aqueous Coating Systems", Spec. Publ.--R.
Soc. Chem. 76 (Addit. Water-Based Coat.), (1990) (Abstract only).
.
Sokolowski, A., "Chemical Structure and Thermodynamics of
Amphiphile Solutions. 2. Effective Length of Alkyl Chain in
Oligooxyalkylenated Alcohols", Colloids Surf., vol. 56 (1991), pp.
239-249 (Abstract only). .
Asgharian, N., P. Otken, C. Sunwoo & W. H. Wade, "Synthesis and
Performance of High-Efficiency Cosurfactants. 1. Model Systems",
Langmuir, vol. 7, No. 12 (1991), pp. 2904-2910. (Abstract only).
.
PCT Search Report dated Jun. 12, 1996, for PCT/US96/02902..
|
Primary Examiner: Hertzog; Ardith
Attorney, Agent or Firm: Yetter; Jerry J. Rasser; Jacobus
C.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No.
08/413,560, filed Mar. 30, 1995, now abandoned.
Claims
What is claimed is:
1. A method for cleaning fabrics, comprising applying to said
fabrics a dry cleaning and spot removal composition,
comprising:
(a) from about 0.01%, to about 0.20%, by weight, of a polyacrylate
emulsifier;
(b) from about 1% to about 30%, by weight, of an organic cleaning
solvent selected from the group consisting of the monomethyl-,
monoethyl-, monopropyl-, and monobutyl-ethers of propoxylated
propanol, and mixtures thereof;
(c) optionally, from about 0.05% to about 5%, by weight, of
detersive surfactant selected from the group consisting of amine
oxides, alkyl ethoxy sulfates, ethoxylated alcohols, and mixtures
thereof surfactants; and
(d) at least about 60%, by weight water.
2. A method according to claim 1 wherein the polyacrylate
emulsifier has a molecular weight in the range from about 100,000
to about 10,000,000.
3. A method according to claim 1 wherein the alkyl ethoxy sulfate
surfactant is in its magnesium salt form.
4. A method according to claim 1 wherein said composition
additionally comprises at least about 0.05%, by weight, of
1,2-octanediol.
5. A method according to claim 1 which is conducted in a hot air
clothes dryer.
Description
FIELD OF THE INVENTION
The present invention relates to emulsified water/solvent dry
cleaning and spot removal compositions which are especially adapted
for use in the home.
BACKGROUND OF THE INVENTION
By classical definition, the term "dry cleaning" has been used to
describe processes for cleaning textiles using nonaqueous solvents.
Dry cleaning is an old art, with solvent cleaning first being
recorded in the United Kingdom in the 1860's. Typically, dry
cleaning processes are used with garments such as woolens which are
subject to shrinkage in aqueous laundering baths, or which are
judged to be too valuable or too delicate to subject to aqueous
laundering processes. Various hydrocarbon and halocarbon solvents
have traditionally been used in dry cleaning processes, and the
need to handle and reclaim such solvents has mainly restricted the
practice of conventional dry cleaning to commercial
establishments.
While solvent-based dry cleaning processes are quite effective for
removing oily soils and stains, they are not optimal for removing
particulates such as clay soils, and may require special treatment
conditions to remove proteinaceous stains. Ideally, particulates
and proteinaceous stains are removed from fabrics using detersive
ingredients and operating conditions which are more akin to aqueous
laundering processes than to conventional dry cleaning.
In addition to the cleaning function, dry cleaning also provides
important "refreshment" benefits. For example, dry cleaning removes
undesirable odors and extraneous matter such as hair and lint from
garments, which are then generally folded or pressed to remove
wrinkles and restore their original shape. Of course, such
refreshment benefits are also afforded by aqueous laundering
processes.
As can be seen from the foregoing, and aside from the effects on
certain fabrics such as woolens, there are no special, inherent
advantages for solvent-based immersion dry cleaning over aqueous
cleaning processes with respect to fabric cleaning or refreshment.
Moreover, on a per-garment basis, commercial dry cleaning is much
more expensive than aqueous cleaning processes.
In contrast with conventional laundry and dry cleaning processes
which involve the total immersion of fabrics into aqueous or
non-aqueous baths, spot removal involves the application of
cleaning ingredients directly to a specific spot or stain, usually
with brisk manual agitation. Traditional spot remover compositions
typically are formulated as sticks or sprays, and can comprise a
variety of cleaning ingredients, including some solvents.
While various dry cleaning compositions have been suggested in the
literature, the majority are designed for use in commercial
immersion dry cleaning processes. Most dry cleaning compositions
contain very little water. By contrast, the compositions herein
employ substantial amounts of water together with organic solvents;
accordingly, it is difficult to prepare stable, homogeneous
mixtures therefrom. While it might be possible to use large amounts
of conventional surfactants to emulsify such water/solvent
mixtures, the resulting compositions would tend to leave
unacceptable levels of residue on fabrics which are cleaned without
a rinse step in the manner disclosed herein.
It has now been discovered that certain polyacrylate materials are
excellent emulsifiers for water/solvent dry cleaning compositions.
Moreover, the polyacrylates are useful at quite low levels, thereby
avoiding the residue problem associated with less effective
materials. The resulting polyacrylate/water/solvent compositions
are smooth and lubricious, and, depending on the solvent employed,
can be formulated to have a mild, inoffensive odor.
Accordingly, it is an object of the present invention to provide
improved compositions for use in cleaning fabrics. It is another
object herein to provide stable water/solvent compositions for use
in home dry cleaning systems. These and other objects are secured
herein, as will be seen from the following disclosures.
BACKGROUND ART
Dry cleaning processes are disclosed in: EP 429,172A1, published
29.05.91, Leigh, et al.; and in U.S. Pat. Nos. 5,238,587, issued
Aug. 24, 1993, Smith, et al. Other references relating to dry
cleaning compositions and processes, as well as wrinkle treatments
for fabrics, include: GB 1,598,911; and U.S. Pat. Nos. 4,126,563,
3,949,137, 3,593,544, 3,647,354; 3,432,253 and 1,747,324; and
German applications 2,021,561 and 2,460,239, 0,208,989 and
4,007,362. Cleaning/pre-spotting compositions and methods are also
disclosed, for example, in U.S. Pat. Nos. 5,102,573; 5,041,230;
4,909,962; 4,115,061; 4,886,615; 4,139,475; 4,849,257; 5,112,358;
4,659,496; 4,806,254; 5,213,624; 4,130,392; and 4,395,261. Sheet
substrates for use in a laundry dryer are disclosed in Canadian
1,005,204. U.S. Pat. Nos. 3,956,556 and 4,007,300 relate to
perforated sheets for fabric conditioning in a clothes dryer. U.S.
Pat. No. 4,692,277 discloses the use of 1,2-octanediol in liquid
cleaners.
SUMMARY OF THE INVENTION
The present invention encompasses a dry cleaning and spot removal
composition, comprising:
(a) at least about 0.01%, by weight, of a polyacrylate
emulsifier;
(b) from about 1% to about 30%, by weight, of an organic
solvent;
(c) optionally, from about 0.05% to about 5%, by weight, of
detersire surfactants; and
(d) water.
The polyacrylate emulsifier is available commercially from a
variety of sources, and preferably has a molecular weight in the
range from about 100,000 to about 10,000,000. The organic solvent
used herein is preferably a member selected from the group
consisting of butoxy propoxy propanol (BPP; preferred herein),
methoxy propoxy propanol (MPP), ethoxy propoxy propanol (EPP),
propoxy propoxy propanol (PPP), and mixtures and all isomers
thereof, although other organic cleaning solvents may be used.
The compositions herein optionally can also comprise a detersire
surfactant which is preferably a member selected from the group
consisting of amine oxides, alkyl ethoxy sulfates, and mixtures
thereof. The alkyl ethoxy sulfate surfactants are preferably in
their magnesium salt form.
In yet another mode, the compositions herein additionally comprise
at least about 0.05%, by weight, of 1,2-octanediol as a highly
preferred wetting agent.
The invention also encompasses a method for cleaning fabrics,
comprising applying to said fabrics a composition according to the
present invention, and especially wherein said method is conducted
in a hot air clothes dryer.
All percentages, ratios and proportions herein are by weight,
unless otherwise specified. All documents cited are, in relevant
part, incorporated herein by reference.
DETAILED DESCRIPTION OF THE INVENTION
The ingredients of the dry cleaning compositions and their use in
the process of the present invention are described seriatim
hereinafter.
Cleaning Compositions--The chemical compositions which are used to
provide the cleaning function in the present dry cleaning process
comprise ingredients which are safe and effective for their
intended use. Since the process herein does not involve an aqueous
rinse step, the cleaning compositions employ ingredients which do
not leave undesirable residues on fabrics when employed in the
manner disclosed herein. Moreover, since the process may be carried
out in a hot air clothes dryer, the compositions contain only
ingredients whose flash points render them safe for such use. The
cleaning compositions preferably do contain some water, since water
not only aids in the cleaning function, but also can help remove
wrinkles and restore fabric drape and appearance, especially in hot
air dryers. While conventional laundry detergents are typically
formulated to provide good cleaning on cotton and cotton/polyester
blend fabrics, the cleaning compositions herein must be formulated
to safely and effectively clean and refresh fabrics such as wool,
silk, rayon, rayon acetate, and the like.
In addition, the cleaning compositions herein comprise ingredients
which are specially selected and formulated to minimize dye removal
from the fabrics being cleaned. In this regard, it is recognized
that the solvents typically used in immersion dry cleaning
processes can remove some portion of certain types of dyes from
certain types of fabrics. However, such removal is tolerable in
immersion processes since the dye is removed relatively uniformly
across the surface of the fabric. In contrast, it has now been
determined that high concentrations of certain types of cleaning
ingredients at specific sites on fabric surfaces can result in
unacceptable localized dye removal. The preferred cleaning
compositions herein are formulated to minimize or avoid this
problem.
The dye removal attributes of the present cleaning compositions can
be compared with art-disclosed cleaners using photographic or
photometric measurements, or by means of a simple, but effective,
visual grading test. Numerical score units can be assigned to
assist in visual grading and to allow for statistical treatment of
the data, if desired. Thus, in one such test, a colored garment
(typically, silk, which tends to be more susceptible to dye loss
than most woolen or rayon substrates) is treated by padding-on
cleaner using an absorbent, white paper hand towel. Hand pressure
is applied, and the amount of dye which is transferred onto the
white towel is assessed visually. Numerical units ranging from: (1)
"I think I see a little dye on the towel"; (2) "I know I see some
dye on the towel"; (3) I see a lot of dye on the towel"; through
(4) "I know I see quite a lot of dye on the towel" are assigned by
panelists.
Having due regard to the foregoing considerations, the following
illustrates the ingredients used in the cleaning compositions
herein, but is not intended to be limiting thereof.
(a) Emulsifier--The compositions will comprise sufficient
polyacrylate emulsifier to provide a stable, homogeneous
composition comprising components (a), (b) and (d). For the
emulsifiers disclosed herein, levels as low as 0.05%, preferably
0.07% to about 0.20%, by weight are effective. Levels above about
0.2% are unnecessary and are preferably not used, thereby avoiding
residues on fabrics.
(b) Solvent--The compositions will comprise at least about 4%,
typically from about 5% to about 25%, by weight, of the solvent.
The objective is to provide at least about 0.4 g, preferably from
about 0.5 g to about 2.5 g, of solvent per kg of fabrics being
cleaned.
(c) Water--The compositions will comprise at least about 60%,
typically from about 80% to about 95%, by weight, of water. Stated
otherwise, the objective is to provide at least about 6 g of water
per kg of fabrics being cleaned.
(d) Optionals--The compositions herein may comprise various
optional ingredients, including perfumes, conventional surfactants,
carriers and the like. If used, such optional ingredients will
typically comprise from about 0.1% to about 10%, by weight, of the
compositions, having due regard for residues on the cleaned
fabrics.
The highly preferred emulsifier herein is commercially available
under the trademark PEMULEN, The B. F. Goodrich Company, and is
described in U.S. Pat. Nos. 4,758,641 and 5,004,557, incorporated
herein by reference. PEMULEN polymeric emulsifiers are high
molecular weight polyacrylic acid polymers. The structure of
PEMULEN includes a small portion that is oil-loving (lipophilic)
and a large water-loving (hydrophilic) portion. The structure
allows PEMULEN to function as a primary oil-in-water emulsifier.
The lipophilic portion adsorbs at the oil-water interface, and the
hydrophilic portion swells in the water forming a network around
the oil droplets to provide emulsion stability. An important
advantage for the use of such polyacrylate emulsifiers herein is
that cleaning compositions can be prepared which contain solvents
or levels of solvents that are otherwise not soluble or readily
miscible with water. A further advantage is that effective
emulsification can be accomplished using PEMULEN-type emulsifier at
extremely low usage levels (0.05-0.2%), thereby minimizing the
level of any residue left on fabrics following product usage. For
comparison, typically about 3-7% of conventional anionic or
nonionic surfactants are required to stabilize oil-in-water
emulsions, which increases the likelihood that a residue will be
left on the fabrics. Another advantage is that emulsification
(processing) can be accomplished effectively at room
temperature.
The preferred solvent herein is butoxy propoxy propanol (BPP) which
is available in commercial quantities as a mixture of isomers in
about equal amounts. The isomers, and mixtures thereof, are all
useful herein. The isomer structures are as follows. (The MPP, EPP
and PPP solvents also exist as isomers and isomer mixtures, all of
which are useful herein.) ##STR1##
BPP is outstanding for cleaning, and is so effective that it allows
the amount of the relatively expensive 1,2-octanediol to be
minimized. Moreover, it allows for the formulation of effective
cleaning compositions herein without the use of conventional
surfactants. Importantly, the odor of BPP is of a degree and
character that it can be relatively easily masked by conventional
perfume ingredients. While BPP is not completely miscible with
water and, hence, could negatively impact processing of the
cleaning compositions herein, that potential problem has been
successfully overcome by means of the PEMULEN-type polyacrylate
emulsifiers, in the manner disclosed herein.
It has now been determined that 1,2-octanediol ("OD") affords
special advantages in the formulation of the cleaning compositions
herein. From the standpoint of aesthetics, OD is a relatively
innocuous and low odor material. Moreover, OD appears to volatilize
from fabric surfaces without leaving visible residues. This is
especially important in a dry cleaning process of the present type
which is conducted without a rinse step. From the performance
standpoint, OD appears to function both as a solvent for
greasy/oily stains and as what might be termed a
"pseudo-surfactant" for particulate soils and water-soluble stains.
Whatever the physical-chemical reason, OD has now been found to be
a superior wetting agent with respect to both cleaning and
ease-of-use in the present context of home-use cleaning
compositions and processes.
The BPP solvent used herein is preferably a mixture of the
aforesaid isomers. In a preferred mode, the cleaning compositions
comprise a mixture of the 1,2-octanediol and BPP, at a weight ratio
of OD:BPP in the range of from about 1:250 to about 2:1, preferably
from about 1:200 to about 1:5. Similar ratios can be used with the
MPP, EPP and PPP solvents.
While the cleaning compositions herein function quite well with
only the emulsifier, the 1,2-octanediol, BPP, PEMULEN and water,
they may also optionally contain detersive surfactants to further
enhance their cleaning performance. While a wide variety of
detersive surfactants such as the C.sub.12 -C.sub.16 alkyl sulfates
and alkylbenzene sulfonates, the C.sub.12 -C.sub.16 ethoxylated (EO
0.5-10 avg.) alcohols, the C.sub.12 -C.sub.14 N-methyl glucamides,
and the like can be used herein, it is highly preferred to use
surfactants which provide high grease/oil removal. Included among
such preferred surfactants are the C.sub.12 -C.sub.16 alkyl ethoxy
sulfates (ALES), especially in their magnesium salt form, and the
C.sub.12 -C.sub.16 dimethyl amine oxides. An especially preferred
mixture comprises MgAE.sub.1 S/MgAE.sub.6.5 S/C.sub.12 dimethyl
amine oxide, at a weight ratio of about 1:1:1. If used, such
surfactants will typically comprise from about 0.05% to about 2.5%,
by weight, of the cleaning compositions herein.
In addition to the preferred solvents and emulsifiers disclosed
above, the cleaning compositions herein may comprise various
optional ingredients, such as perfumes, preservatives, co-solvents,
brighteners, salts for viscosity control, pH adjusters or buffers,
anti-static agents, softeners, colorants, mothproofing agents,
insect repellents, and the like.
Carrier--When used in a dry cleaning operation, the cleaning
compositions are preferably used in combination with a carrier,
such that the cleaning composition performs its function as the
surfaces of the fabrics being cleaned come in contact with the
surface of the carrier.
The carrier can be in any desired form, such as powders, flakes,
shreds, and the like. However, it will be appreciated that such
comminuted carriers would have to be separated from the fabrics at
the end of the cleaning process. Accordingly, it is highly
preferred that the carrier be in the form of an integral pad or
sheet which substantially maintains its structural integrity
throughout the cleaning process. Such pads or sheets can be
prepared, for example, using well-known methods for manufacturing
non-woven sheets, paper towels, fibrous batts, cores for bandages,
diapers and catamenials, and the like, using materials such as wood
pulp, cotton, rayon, polyester fibers, and mixtures thereof. Woven
cloth pads may also be used, but are not preferred over non-woven
pads due to cost considerations. Integral carrier pads or sheets
may also be prepared from natural or synthetic sponges, foams, and
the like.
The carriers are designed to be safe and effective under the
intended operating conditions of the present process. The carriers
must not be flammable during the process, nor should they
deleteriously interact with the cleaning composition or with the
fabrics being cleaned. In general, non-woven polyester-based pads
or sheets are quite suitable for use as the carrier herein.
The carrier used herein is most preferably lint-resistant. By
"lint-resistant" herein is meant a carrier which resists the
shedding of visible fibers or microfibers onto the fabrics being
cleaned, i.e., the deposition of what is known in common parlance
as "lint". A carrier can easily and adequately be judged for its
acceptability with respect to lint-resistance by rubbing it on a
piece of dark blue woolen cloth and visually inspecting the cloth
for lint residues.
The lint-resistance of sheet or pad carriers used herein can be
achieved by several means, including but not limited to: preparing
the carrier from a single strand of fiber; employing known bonding
techniques commonly used with nonwoven materials, e.g., point
bonding, print bonding, adhesive/resin saturation bonding,
adhesive/resin spray bonding, stitch bonding and bonding with
binder fibers. In an alternate mode, a carrier can be prepared
using an absorbent core, said core being made from a material
which, itself, is not lint-resistant. The core is then enveloped
within a sheet of porous, lint-resistant material having a pore
size which allows passage of the cleaning compositions, but through
which lint from the core cannot pass. An example of such a carrier
comprises a cellulose or polyester fiber core enveloped in a
non-woven polyester scrim.
The carrier should be of a size which provides sufficient surface
area that effective contact between the surface of the carrier and
the surface of the fabrics being cleaned is achieved. Of course,
the size of the carrier should not be so large as to be unhandy for
the user. Typically, the dimensions of the carrier will be
sufficient to provide a macroscopic surface area (both sides of the
carrier) of at least about 360 cm.sup.2, preferably in the range
from about 360 cm.sup.2 to about 3000 cm.sup.2. For example, a
rectangular carrier may have the dimensions (x-direction) of from
about 20 cm to about 35 cm, and (y-direction) of from about 18 cm
to about 45 cm.
The carrier is intended to contain a sufficient amount of the
cleaning composition to be effective for its intended purpose. The
capacity of the carrier for the cleaning composition will vary
according to the intended usage. For example, carrier/cleaning
composition pads or sheets which are intended for a single use will
require less capacity than such pads or sheets which are intended
for multiple uses. For a given type of carrier the capacity for the
cleaning composition will vary mainly with the thickness or
"caliper" (z-direction; dry basis) of the sheet or pad. For
purposes of illustration, typical single-use polyester sheets used
herein will have a thickness in the range from about 0.1 mm to
about 0.7 mm and a basis weight in the range from about 30
g/m.sup.2 to about 100 g/m.sup.2. Typical multi-use polyester pads
herein will have a thickness in the range from about 0.2 mm to
about 1.0 mm and a basis weight in the range from about 40
g/m.sup.2 to about 150 g/m.sup.2. Open-cell sponge sheets will
range in thickness from about 0.1 mm to about 1.0 mm. Of course,
the foregoing dimensions may vary, as long as the desired quantity
of the cleaning composition is effectively provided by means of the
carrier.
Container--The present cleaning process is conducted using a
flexible container. The fabrics to be cleaned are placed within the
container with the carrier/cleaning composition article, and the
container is agitated, thereby providing contact between the
carrier/cleaning composition and the surfaces of the fabrics.
The flexible container used herein can be provided in any number of
configurations, and is conveniently in the form of a flexible
pouch, or "bag", which has sufficient volume to contain the fabrics
being cleaned. Suitable containers can be manufactured from any
economical material, such as polyester, polypropylene, and the
like, with the proviso that it must not melt if used in contact
with hot dryer air. It is preferred that the walls of the container
be substantially impermeable to water vapor and solvent vapor under
the intended usage conditions. It is also preferred that such
containers be provided with a sealing means which is sufficiently
stable to remain closed during the cleaning process. Simple tie
strings or wires, various snap closures such as ZIP LOK.RTM.
closures, and VELCRO.RTM.-type closures, contact adhesive, adhesive
tape, zipper-like closures, and the like, suffice.
The container can be of any convenient size, and should be
sufficiently large to allow tumbling of the container and fabrics
therein, but should not be so large as to interfere with the
operation of the tumbling apparatus. With special regard to
containers intended for use in hot air clothes dryers, the
container must not be so large as to block the air vents. If
desired, the container may be small enough to handle only a single
shirt, blouse or sweater, or be sufficiently large to handle a
man's suit.
Process--The present cleaning process can be conducted in any
manner which provides mechanical agitation, such as a tumbling
action, to the container with the fabrics being cleaned. If
desired, the agitation may be provided manually. However, in a
convenient mode a container with the carrier/cleaning composition
and enveloping the soiled fabric is sealed and placed in the drum
of an automatic clothes dryer. The drum is allowed to revolve,
which imparts a tumbling action to the container and agitation of
its contents concurrently with the tumbling. By virtue of this
agitation, the fabrics come in contact with the carrier releasably
containing and carrying the cleaning composition. It is preferred
that heat be employed during the process. Of course, heat can
easily be provided in a clothes dryer. The tumbling and optional
(but preferred) heating is carried out for a period of at least
about 10 minutes, typically from about 20 minutes to about 30
minutes. The process can be conducted for longer or shorter
periods, depending on such factors as the degree and type of
soiling of the fabrics, the nature of the soils, the nature of the
fabrics, the fabric load, the amount of heat applied, and the like,
according to the needs of the user. The following illustrates a
typical process in more detail, but is not intended to be limiting
thereof .
EXAMPLE I
A dry cleaning article in sheet form is assembled using a sheet
substrate and a cleaning composition prepared by admixing the
following ingredients.
______________________________________ Ingredient % (wt.)
______________________________________ PEMULEN TR-1* 0.15 BPP** 7.0
1,2-octanediol 0.5 Surfactant Mixture* 0.50 KOH 0.08 Perfume 0.75
Water Balance ______________________________________ *PEMULEN TR2,
B. F. Goodrich, may be substituted **Isomer mixture, available from
Dow Chemical Co. ***Mixture of MgAE.sub.1 S, MgAE.sub.6.5 S and
C.sub.12 amine oxide, in the range of 1:1:1 to 0.5:1:1.
A non-linting carrier sheet is prepared using a non-woven, two-ply
fabric stock comprising polyester fibers, caliper 0.25 mm to 0.34
ram, basis weight 84 g/m.sup.2. The fabric is cut into square
carrier sheets, approximately 25 cm on a side, i.e., 625 cm.sup.2
sheets. Three or four rows of regularly-spaced 1.27 cm (0.5 in.)
diameter circular holes are punched through the sheet. (The
finished sheet can later be folded for packaging, and when unfolded
and used in the manner disclosed herein, the holes help maintain
the sheet in the desired unfolded configuration.)
23 Grams of the above-noted cleaning composition are evenly applied
to the sheet by spreading onto the sheet with a roller or spatula
using hand pressure. In an alternative mode, the cleaning
composition can be applied by dipping or spraying the composition
onto the substrate, followed by squeezing with a roller or pair of
nip rollers, i.e., by "dip-squeezing" or "spray squeezing". The
external surfaces of the sheet are damp but not tacky to the
touch.
A dry cleaning sheet of the foregoing type is unfolded and placed
flat in a plastic bag having a volume of about 25,000 cm.sup.3
together with about 2 kg of dry garments to be cleaned. The bag is
closed, sealed and placed in a conventional hot-air clothes dryer.
When the garments and the dry cleaning sheet are placed in the bag,
the air is preferably not squeezed out of the bag before closing
and sealing. This allows the bag to billow, thereby providing
sufficient space for the fabrics and cleaning sheet to tumble
freely together. The dryer is started and the bag is tumbled for a
period of 20-30 minutes at a dryer air temperature in the range
from about 50.degree. C. to about 85.degree. C. During this time,
the dry cleaning sheet remains substantially in the desired open
position, thereby providing effective contact with the fabrics.
After the machine cycle is complete, the bag and its contents are
removed from the dryer, and the spent dry cleaning sheet is
discarded. The plastic bag is retained for re-use. The garments are
cleaned and refreshed. The water present in the cleaning
composition serves to minimize wrinkles in the fabrics.
In an alternate mode, heavily soiled areas of the fabric being
cleaned can optionally be pre-treated by pressing or rubbing a
fresh dry cleaning sheet according to this invention on the area.
The sheet and pre-treated fabric are then placed in the container,
and the dry cleaning process is conducted in the manner described
herein.
The compositions prepared in the manner of this invention can also
be directly applied to isolated spots and stains on fabrics in the
manner of a spot remover product. The following illustrates this
aspect of the invention, but is not intended to be limiting
thereof.
EXAMPLE II
A spot remover composition comprises the following:
______________________________________ Ingredients % (wt.)
______________________________________ PEMULEN 0.15 BPP* 7.0
1,2-Octanediol 0.5 Perfume 0.75 Water Balance
______________________________________ *May be replaced by an
equivalent amount of MPP, EPP and PPP, respectively, or mixtures
thereof, and mixtures thereof with BPP.
The composition is directly padded or sprayed onto spots and
stains, followed by rubbing, to effect their removal. In an
alternate mode, the composition can be gelled or thickened using
conventional ingredients to provide a "stick-form" spot
remover.
Having thus described and exemplified the present invention, the
following further illustrates various cleaning compositions which
can be formulated and used in the practice thereof.
EXAMPLE III
______________________________________ Ingredient % (wt.) Formula
Range ______________________________________ BPP* 5-25%
1,2-Octanediol 0.1-7% MgAE.sub.1 S 0.01-0.8% MgAE.sub.6.5 S
0.01-0.8% C.sub.12 Dimethyl Amine Oxide 0.01-0.8% PEMULEN**
0.05-0.20% Perfume 0.01-1.5% Water Balance
______________________________________ pH Range from about 6 to
about 8. *Other cosolvents which can be used herein together with
the BPP, MPP, EP and PPP primary solvents include various glycol
ethers, including materials marketed under trademarks such as
Carbitol, methyl Carbitol, butyl Carbitol, propyl Carbitol, hexyl
Cellosolve, and the like. If desired, and having due regard for
safety and odor for inhome use, variou conventional chlorinated and
hydrocarbon dry cleaning solvents may also b used. Included among
these are 1,2dichloroethane, trichloroethylene, isoparaffins, and
mixtures thereof. **As disclosed in U.S. Pat. Nos. 4,758,641 and
5,004,557, such polyacrylates include homopolymers which may be
crosslinked to varying degrees, as well as noncrosslinked.
Preferred herein are homopolymers having a molecular weight in the
range of from about 100,000 to about 10,000,000, preferably 200,000
to 5,000,000.
Excellent cleaning performance is secured using any of the
foregoing non-immersion processes and articles to provide from
about 5 g to about 50 g of the cleaning compositions per kilogram
of fabric being cleaned. Use of the polyacrylate emulsifier at the
indicated low levels minimizes residues on the fabrics.
EXAMPLE IV
A dry cleaning composition with reduced tendency to cause dye
"bleeding" or removal from fabrics as disclosed above is as
follows.
______________________________________ INGREDIENT PERCENT (wt.)
(RANGE) ______________________________________ Butoxypropoxy
propanol (BPP) 7.000 4.0-25.0% NEODOL 23 - 6.5* 0.750 0.05-2.5%
1,2-Octanediol 0.500 0.1-10.0% Perfume 0.750 0.1-2.0% Pemulen TR-1
0.125 0.05-0.2% Potassium Hydroxide (KOH) 0.060 0.024-0.10
Potassium Chloride 0.075 0.02-0.20 Water (distilled or deionized)
90.740 60.0-95.0% Target pH = 7.0
______________________________________ *Shell; C.sub.12 C.sub.13
alcohol, ethoxylated with average EO of 6.5.
15-25 Grams of a composition of the foregoing type are placed on a
carrier sheet for use in the manner disclosed herein. A preferred
carrier substrate comprises a binderless (or optional low binder),
hydroentangled absorbent material, especially a material which is
formulated from a blend of cellulosic, rayon, polyester and
optional bicomponent fibers. Such materials are available from
Dexter, Non-Wovens Division, The Dexter Corporation as
HYDRASPUN.RTM., especially Grade 10244. The manufacture of such
materials forms no part of this invention and is already disclosed
in the literature. See, for example, U.S. Pat. Nos. 5,009,747,
Viazmensky, et al., Apr. 23, 1991 and 5,292,581, Viazmensky, et
al., Mar. 8, 1994, incorporated herein by reference. Preferred
materials for use herein have the following physical
properties.
______________________________________ Grade Optional 10244 Targets
Range ______________________________________ Basis Weight
gm/m.sup.2 55 35-75 Thickness microns 355 100-1500 Density gm/cc
0.155 0.1-0.25 Dry Tensile gm/25 mm MD 1700 400-2500 CD 650 100-500
Wet Tensile gm/25 mm MD* 700 200-1250 CD* 300 100-500 Brightness %
80 60-90 Absorption Capacity % 735 400-900 (H.sub.2 O) Dry Mullen
gm/cm.sup.2 1050 700-1200 ______________________________________
*MD -- machine direction; CD -- cross direction
As disclosed in U.S. Pat. Nos. 5,009,747 and 5,292,281, the
hydroentangling process provides a nonwoven material which
comprises cellulosic fibers, and preferably at least about 5% by
weight of synthetic fibers, and requires less than 2% wet strength
agent to achieve improved wet strength and wet toughness.
Surprisingly, this hydroentangled carrier is not merely a passive
absorbent for the cleaning compositions herein, but actually
optimizes cleaning performance. While not intending to be limited
by theory, it may be speculated that this carrier is more effective
in delivering the cleaning composition to soiled fabrics. Or, this
particular carrier might be better for removing soils by contact
with the soiled fabrics, due to its mixture of fibers. Whatever the
reason, improved dry cleaning performance is secured.
In addition to the improved cleaning performance, it has now been
discovered that this hydroentangled carrier material provides an
additional, unexpected benefit due to its resiliency. In-use, the
dry cleaning sheets herein are designed to function in a
substantially open configuration. However, the sheets are packaged
and sold to the consumer in a folded configuration. It has been
discovered that carrier sheets made from conventional materials
tend to undesirably revert to their folded configuration in-use.
This undesirable attribute can be overcome by perforating such
sheet, but this requires an additional processing step. It has now
been discovered that the hydroentangled materials used to form the
carrier sheet herein do not tend to re-fold during use, and thus do
not require such perforations (although, of course, perforations
may be used, if desired). Accordingly, this newly-discovered and
unexpected attribute of the carrier materials herein makes them
optimal for use in the manner of the present invention.
A sheet of the foregoing type is placed together with the fabrics
to be dry cleaned in a flexible containment bag having dimensions
as noted hereinabove and sealing means. In a preferred mode, the
containment bag is constructed of thermal resistant film in order
to provide resistance to hot spots (350.degree. F.-400.degree. F.;
177.degree. C. to 204.degree. C.) which can develop in some dryers.
This avoids internal self-sealing and external surface deformation
of the bag, thereby allowing the bag to be re-used.
In a preferred embodiment, 0.0025 mm to 0.0075 mm thickness nylon
film is converted into a 26 inch (66 cm).times.30 in. (76 cm) bag.
Bag manufacture can be accomplished in a conventional manner using
standard impulse heating equipment, air blowing techniques, and the
like. In an alternate mode, a sheet of nylon is simply folded in
half and sealed along two of its edges.
In addition to thermally stable "nylon-only" bags, the containment
bags herein can also be prepared using sheets of co-extruded nylon
and/or polyester or nylon and/or polyester outer and/or inner
layers surrounding a less thermally suitable inner core such as
polypropylene. In an alternate mode, a bag is constructed using a
nonwoven outer "shell" comprising a heat-resistant material such as
nylon or polyethylene terephthalate and an inner sheet of a polymer
which provides a vapor barrier. The non-woven outer shell protects
the bag from melting and provides an improved tactile impression to
the user. Whatever the construction, the objective is to protect
the bag's integrity under conditions of thermal stress at
temperatures up to at least about 400.degree.-500.degree. F.
(204.degree. C. to 260.degree. C.). Nylon VELCRO.RTM.-type,
ZIP-LOK.RTM.-type and/or zipper-type closures can be used to seal
the bag, in-use.
Besides the optional nonionic surfactants used in the cleaning
compositions herein, which are preferably C.sub.8 -C.sub.18
ethoxylated (E01-15) alcohols or the corresponding ethoxylated
alkyl phenols, the compositions contain enzymes to further enhance
cleaning performance. Lipases, amylases and protease enzymes, or
mixtures thereof, can be used. If used, such enzymes will typically
comprise from about 0.001% to about 5%, preferably from about 0.01%
to about 1%, by weight, of the composition. Commercial detersive
enzymes such as LIPOLASE, ESPERASE, ALCALASE, SAVINASE and TERMAMYL
(all ex. NOVO) and MAXATASE and RAPIDASE (ex. International
Bio-Synthesis, Inc.) can be used.
If an antistatic benefit is desired, the compositions used herein
can contain an anti-static agent. If used, such anti-static agents
will typically comprise at least about 0.5%, typically from about
2% to about 8%, by weight, of the compositions. Preferred
anti-stats include the series of sulfonated polymers available as
VERSAFLEX 157, 207, 1001, 2004 and 7000, from National Starch and
Chemical Company.
The compositions herein can optionally be stabilized for storage
using conventional preservatives such as KATHON.RTM. at a level of
0.001%-1%, by weight.
If the compositions herein are used in a spot-cleaning mode, they
are preferably pressed (not rubbed) onto the fabric at the spotted
area using an applicator pad comprising looped fibers, such as is
available as APLIX 200 or 960 Uncut Loop, from Aplix, Inc.,
Charlotte, N.C. An underlying absorbent sheet or pad of looped
fibers can optionally be placed beneath the fabric in this mode of
operation.
* * * * *